Transcript Presentation

International Future Energy Challenge
Integrated starter/alternator topic
IFEC ‘07
Page 1
Program Vision

Encourage development of technologies to bring
dramatic improvements to low-cost 4-Q ASMD for
integrated S/A application.

Incorporate practicality, manufacturability,
affordability into competition process

Improve undergraduate education through
development of innovative team-based solutions to
complex problems
Page 2
Technical Goals
t
e
x
t
t
e
x
t
4-Q Dynamometer
t
e
x
t
t
e
text
x
t
t
e
x
t
t
e
x
t
Machine Under Test
(MUT)
text
MUT Controller
Dynamometer Controller
A
L
A
B
L
B
DC Power Source
A
L
B
Figure 1. Functional Block Diagram of Test Set up
Page 3
Technical Goals
Mechanical Interface
It is very important to have proper mounting and accurate
alignment for safe operation of the whole set up. MUT
mounting dimension should be in accordance with NEMA 56
frame size for foot mounting configuration. MPC test set up
shall have matching dimensions to couple MUT confirming
NEMA 56 frame size with foot mounting configuration. It is
very important to observe these dimensions and verify
that MUT dimensions match NEMA 56 frame size because any
deviation may cause the MUT not to mount on MPC test set up.
Such a situation may lead to being unable to test
the MUT.
Page 4
Technical Goals
(+) DC Bus
DC Power Source
Dynamometer Controller
A
L
A
B
(-) DC Bus
B
L
A
MUT Controller
A
L
B
B
Student Team Hardware
C
Dynamic Braking Resistor
Figure 2. Electrical Interfacing
Page 5
Technical Goals
Electrical Interface:
Assuming screw type terminal strips on prototype ,
these connections will be flying leads without any termination with
appropriate cable size suitable to the power ratings.
Please notify us immediately if competition specifications
are otherwise for these electrical interfacing.
DC bus voltage monitoring and control and brake IGBT/MOSFET
are part of the prototype. . Input power supply shall have a current
limit set to 20 ampere in order to protect against higher current under
any adverse situation.
Page 6
Technical Goals
Speed
Region - 1
Region - 2
Region - 3
3000 RPM
2500 RPM
Drawing Not to Scale
300 RPM
0 RPM
Time
1 Second
5 Second
Speed profile for testing
Page 7
Technical Goals
Test Methodology
There are three key areas of qualitative assessments:
• Capability to start under 30 Nm load as starter
• Reach the speed up to 3000 RPM as starter
• Smoothly transition from starter to generator and charge
the batteries at 3000 rpm
Page 8
Technical Goals
Durability Test
At the end of the day, all qualified hardware will be tested for durability.
Fan blades may be mounted on the shaft to provide a nominal load.
The motor will start from rest. The set up will be observed for 10
minutes to ensure safety and then will be left to run for about 30
minutes at the least. There will be no measurements/data
acquisition/monitoring of these systems during durability test.
The only protection to the set up will be the individual circuit breaker
on the input power supply to each UUT. Finalists are recommended
to verify their set up for such continuous run during their trials to
ensure everything runs as planned at the time of final competition.
Page 9
Judging

Judges will be experts from machine/drive
industry

Design, operating documentation, test results,
presentation, final report (including cost analysis)
all considered

Development of point structure requires team
participation
Page 10
Rule Issues

Repair or maintenance work on hardware on site
must be approved by judges

Units with major failures or obvious severe
shipping damage may not be approved for testing

Once at MPC, hardware may not be taken off site

Appeals of rulings can be made to full judging
committee – their decisions are final

Teams must follow safety regulations established
by MPC and IFEC.
Page 11
Prizes

Highest in team scoring will have detailed cost
evaluation by industry experts

Expected prizes include $10k grand prize, and
several category prizes ($5k/prize).

There is an design innovation award for creativity
in design and control of ASMD. This award will be
presented at IECON 2009 (Portugal).
Page 12
A Few Points to Remember

Suggested Policy Points:

Students to work at least in pairs.

When full ac wall potential is in use, a faculty
member or TA must be present. At least two
people must be present.

No food or drink at lab benches.
Page 13
A Few Points to Remember

Shock hazards exist in any labs.

Most likely problems are with spilled drinks or
careless wiring.

Loose clothing and neckties are a problem when
motors are used.

It only takes a watt to make small parts hot.

Often metal cases are live.
Page 14
A Few Points to Remember

Serious power electronics work –

Safety glasses

Fire extinguishers

A safety plan, to include circuit protection
Page 15
A Few Points to Remember
– Turn power off when making circuit changes.
– Keep a tight, neat setup. (It is safer, easier to debug, and
just plain works better.)
– Treat part cases as live or hot.
– When in doubt, shut power off.
– If it doesn’t work, it probably isn’t the instrument.
Page 16
A Few Points to Remember

Equipment damage is a common safety issue.

Problem areas:
– Grounding. Students often don’t understand limitations of
grounded probes or sources.
– Ratings. Do instrument ratings match the signal?
Page 17